Electrical connector



April 1963 s. E. GREGOIRE ElAL 3,084,303

ELECTRICAL CONNECTOR Original Filed Oct. 1, 1957 y mi M Nwwfl E D c 0 W 1 IWJAM/ 5. way .5 s W I 5 V. B

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This invention relates to electrical apparatus and more particularly to means for effecting terminal connections between electrical conductors.

This application is a division of application Serial No. 687,417, filed October 1, 1957, now Patent No. 2,982,937, issued May 2, 1961.

One of the objects of the present invention is to provide a novelly constructed electrical terminal which will provide a satisfactory electrical connection throughout a Wide range of temperatures and at substantially high temperatures.

Another object of the invention is to provide novel cooperating male and female electrical terminals for effecting a connection between conductors in hermetically sealed units.

Another object is to provide electrical terminal means wherein parts having different coeflicients of expansion are novelly constructed and assembled to compensate for expansion and contraction of such parts resulting from temperature variations extending from below 65 F. to 1000 F. and more.

The above and further objects and novel features of the present invention will more fully appear from the following detail description when the same is read in connection with the accompanying drawings. It is to be expressly understood, however, that the drawings are for the purpose of illustration only and are not intended as a definition of the limits of the invention.

In the drawings, wherein like reference characters refer to like parts throughout the several views,

FIG. 1 is an elevation view, mostly in section and with parts broken away, showing one form of electrical connector means embodying the present invention; and

FIG. 2 is a detail elevation view of a part of said terminal.

The single embodiment of the invention illustrated in the accompanying drawings, by way of example, is in the form of separable or detachable connector means adapted for making an electrical connection between electrical conductors in hermetically sealed containers or conduits. The novel construction shown is designed to Withstand the high temperatures encountered in use on jet type engines, missiles and the like and to hermetically seal an insulated conductor in a flexible shielding conduit for protection against electrical fiZiSJOVfiiS at low atmospheric pressures occurring at high altitudes.

In the form illustrated, the socket contact assembly of the novel structure contemplated by the invention comprises a tubular metallic shell iii hermetically secured in an opening of a casing 11. The shell and casing may be integral if desired. A tube or sleeve 12 of heat resistant refractory insulating material is novelly supported or suspended in shell 16 in radially spaced relation thereto, and the annular space between the two is hermetically sealed by a flanged metal tube 14 which may be made, for example, of nickel, nickel plated steel, stainless steel, or other suitable metal. The tube 14 comp-rises a cylindrical portion 15, a central cone-like portion 16 and an external annular flange 17 which engages and is soldered or brazed throughout its circumference to a downwardly facing shoulder in shell 1%. Within cylindrical portion 15, insulating tube 12 is provided with a metallic surface coating 3,d84,3fl3 Patented Apr. 2, 1953 to which said cylindrical portion is circumferentially brazed by means of a fine silver or nickle braze. The central cone-like portion 16 and the inner unsecured portion of flange 17 function as a flexible diaphragm which absorbs or compensates for diiferences in the expansion and contraction of the various assembled parts when the same are subjected to wide variations of temperature. A hermetic seal is also formed by member 14 between insulator 12 and shell 10.

A novel socket contact assembly is provided within and hermetically seals the bore through insulating tube 12. Said assembly comprises an inverted cup-like metallic member 18 having a cylindrical portion 19 and an internal flange 20 connected by a cone-like portion 21. Cylindrical portion 19 is circumferentially brazed to a metallic coating on the inner surface of the end portion of insulating tube .12. A cup-like socket contact 22 has a clearance fit in the bore of insulator 12 and engages the closed end of member 18. The adjacent ends of cup members 18 and 22 are preferably provided with matching holes for receiving a rigid pin 23 which may function as a rivet mechanically connecting said members and as a connector for a conductor within casing '11. The parts may be silver soldered or brazed together around the pin-receiving hole to complete the hermetic sealing of the bore of insulator 12. Member 18 functions as a diaphragm while member 22 is slidable in tube 12 to compensate for relative movement of the parts caused by expansion and contraction caused by the heating and cooling of the parts in operation. Cup member 22 is advantageously made of nickel or is nickel plated to prevent its becoming oxidized during use.

The plug or male terminal of the connector is likewise novelly constructed to function with complete satisfaction at high as well as low temperatures and to provide an hermetic end seal for a conductor conduit. As shown, the lead assembly embodying the plug terminal comprises a conductor 24 covered with electrical insulation 25 which will withstand high temperatures. In one suitable embodiment, conductor 2-4 was wrapped with tape consisting of ceramic fibers in sheet form laminated with glass cloth and covered with one or more braided layers of yarn made of silica fibers. The insulated conductor may be covered by a tube 26 of woven metallic strands. Surrounding the shielded cable above described, is a flexible, impervious conduit comprising a corrugated metal tube 27 covered by a braided metal tube 28. The ends of tubes 27 and 28 are connected together, such as by heliarc welding, in a welded assembly with a ring 255 and a metal sleeve 30 to form an hermetically sealed joint. The braided cover 26 of the cable is cut off short of the end of insulated conductor 24, 25 and is circumferentially fanned out at 31 to lie between ring 2% and the end of a metal tube 32. The engaging par-ts are welded, as by heliarc Welding, to form an hermetically sealed joint.

The insulated conductor 24, 25 extends into a ceramic tube 33 which is novelly suspended or supported within and in radially spaced relation to metal tube 32 by a metal diaphragm 34. The latter may consist of two cylindrical portions 35 and 36, one of which fits into and is circumferentially brazed to metal tube 32, and the other of which surrounds and is brazed to an external metallic coating on the end portion of ceramic tube '33. The cylindrical portions 35, 36 are integrally joined by a conical portion 317 which provides for any necessary relative movement or expansion between the connected parts when the same are subjected to temperature variations.

The lower or outer end portion of insulating sleeve 36, as viewed in the drawing, is of reduced diameter for passing an uninsulated end portion of conductor 24. Surrounding said reduced end portion and brazed to a metallic coating thereon in a hermetic manner is a tubular metallic tip or nose piece 38, the end of which preferably extends beyond ceramic tube 33. Conductor 24 extends beyond the tip piece and through a central opening in the bottom of a cup-shaped; male contact terminal 39, and the three are heliarcor otherwise suitably welded to form an hermetic seal at the end of the bore. through; tip piece 38.

Contact member 353 has the side walls thereof slotted to form a plurality of resilient fingers 4% (FIG. 2) and is adapted to slidably fit into socket contact 22 for electrical contact therewith. For. the purpose of assuring firm and good electrical contact between fingers til-and socket 22 under high heatv conditions, contact terminal 3-9--rnay, be of bi-metal construction and of such a naturethatfiflgfirs 40 will bend or push. outwardly when subjected to heat. Preferably, however, contact member 39 is fabricated from soft annealed nickel orthe like and a split annular bimetallic member 41 capable of withstanding extremely high temperatures is provided within terminal member 39 and held against axial displacement by an annular groove 42 in tip piece 38; Member il'exertssome expansive force uponmember 39 at room temperature, to assure good contact between members 39 and 22. When subjected to high temperatures, the bi-metallic member 41 expands to maintain fingers 40 in firm and good electrical contact with socket contact 22. r

The connector parts may be positively held in; assembled position by detachable means, asshown. A flanged nut 44 fits over and contactsthe edge of a flange 45 'on housing member 32. The nut has. threaded engagement at 46 with the confronting end of housing ML-thereby to drawand maintain the two housings together. Ifdesired, the two housings may be sealed to each other by an annular sealingring 49 whichis carriedin a seat on. the end of housing and is compressed between the ends; of'the housings. Housing 32 may be extended, if desired, in a circular cylindrical portion 47'which lies between housing 110 and tubular insulator 12. Portion 47' aids in thepreliminaryaligning of the connector parts upon their assembly, and also functions to -guard the parts ofthe male or pin connector against injury when it is disconnected and withdrawn from socket 22 and housing 10.

Although only one embodiment of the invention has been illustrated in the accompanying drawings and described in the foregoing specification, it is to be expressly understood that various changes, such as in the relative dimensions in the parts, materials used, and'the like as Well as the suggested mannerof meat the apparatus of the invention, may be made therein without departing from the spirit and scope of the invention as will now be apparent to those skilled; in the art.

What-is claimed is:

l. -A separable electrical connector comprising in combination a socket contact and a pin contact adapted to be received within and make electrical contact with the socket contact, a conductor for said pin contact, said pin contact comprising a plurality of resilient finger members secured to said conductor and radially spaced from and extending axially of said conductor with the external snr-' faces thereof adapted to engage said socket contact, heatexpansible means positioned between said conductor and said finger members andadapted to contact the internal surface of said finger members upon expansion whereby said finger members are held in, contact with said socket contact throughout an extended range of ambient temperatures.

2. An electrical connector as defined in claim .1 comprising means on said conductor to prevent the axial displacement of said heat-expansible means.

3. A separable electrical connector comprising in combination a socket contact and a pin contact adapted to be received within and make electrical contactflwith the.

socket contact, an axially extending conductor, said pin contact comprising a plurality of finger members radially displaced from said conductor and electrically connected thereto, a h eat-expansible member positioned between each of said finger members and said conductor whereby upon a rise in temperature said heat-expansible member will expand and back up said finger members.

4. A separable electrical connector comprising in combination a socket contact and a pin contact adapted to be received Within and make electrical contact with the socket contact, a central axially extending conductor, the pin contact being generally cup shaped and telescopically positioned over the end of said conductor, and having a transverse bottom portion and, longitudinally slotted sidewall-portions, a bimetallic member positioned coaxially of said conductor and radially inwardly of the sidewall of said pin contact, said bimetallic member being expansible upon a rise in temperature and backing up the sidewall of the pin contact.

5. A separable electrical. connector comprising in combination a socket contact and a pin contact adapted to be received within and make electrical contact with the socket contact, a first axially extending conductor electrically connected to said socket contact, asecond axially extending conductor electrically connected tosaid pin Contact, means to mount said; first conductor and socket cont-act for axial movement relative to the pin contact upon a rise in temperature, means to mount said second conductor and pin contact for axial movement relativeto the socket cont-act upon arise in temperature, said pin contact comprising a plurality of finger portions radially defiectable toward said socket contact and means to cause said finger portions to be radially urged against said socket contact upon a rise in temperature.

6. A separable electrical connector comprising in combination a'socket contact and a pin contact adapted to be received within and make electrical contact with the socket contact, a first axially extending conductor electrically connected'to said socket contact, a second axially extendingconductor electrically connected to said pin contact, means to mount said first conductor and socket contact for axial movement relative to the pin contact upona rise intemperature, means to mount said second? conductor and pin contact for axial movement relative to the socket contact upona rise in temperature, said pin contact having a plurality of finger portions radially displaced from. said second conductor and radially deflectable toward said socket contact, and a heat-expansible member retained adjacent a surface of said. finger portions whereby upon arise in temperature said member will expand and back up each of said finger portions.

7. A separable electrical connector comprising incombination a socket contact and a pin contact adapted to be received within and make electrical contact with the socket contact, the pin contact being hollowand having a relatively thin sidewall which is longitudinally slotted to provide portions generally radially deflectable toward the other contact, and a generally annular bimetallic memberpositioned coaxially of the pin contact and radially inwardly of the sidewall thereof, said annular member being expansible upon. a rise in temperature and backing up the sidewall ofthe pin contact.

8. A separable electrical connector as claimed in claim 7, comprising a hollow, axially extending substantially rigid'insulating member, the pin contact including a radially outer member which is generally cup shaped; said outer member being centrally telescoped over the end of the insulating member, and means on the insulating member positioning the annular bimetallic member axially of the insulating member, said last named means having a transverse portion secured to -abutthe end of the insulating member. a

9. A separable electrical connector as claimed in claim 8, wherein the means positioning the annular bimetallic member has an annular seat for said bimetallic member spaced axially from the bottom portion of said outer member, said annular seat loosely receiving the'annular bimetallic member to allow the latter appreciable freedom of movement in axial and radial directions.

10. A separable electrical connector as claimed in claim 9, wherein the insulating member is tubular, and comprising a conductor extending axial-1y within the insulating member and electrically connected to the bottom portion of said cup-shaped outer member.

11. A separable electrical connector as claimed in claim 10, wherein the insulating member is a ceramic tube, and comprising an outer tubular metallic shell disposed coaxially of and spaced radially outwardly from the ceramic tube, and means sealingly connecting the shell and the ceramic tube, said last named means comprising a flexible annular metallic diaphragm having its radially outer larger diametered edge portion bonded to the shell and its radially inner smaller diametered edge portion bonded to the ceramic tube.

12. A separable electrical connector as claimed in claim 11, comprising a second outer tubular shell adapted to be aligned with and sealed to the first recited shell, a second elongated ceramic tube positioned coaxially of and spaced radially inwardly of the second shell, the socket contact being centrally positioned Within and sealingly connected to the second ceramic tube, and resilient diaphragm means sealingly connecting the second ceramic tube to the second shell, the inner end of the first ceramic tube being telescoped within the inner end of the second ceramic tube when the two shells are in confronting sealed position and the pin contact is telescoped within the socket contact.

13. An electrical connector as defined in claim 3, wherein said heat-expansib-le member is a bimetallic member.

References Cited in the file of this patent UNITED STATES PATENTS 1,635,832 Gagnon July 12, 1927 2,339,329 Funk Jan. 18, 1944 FOREIGN PATENTS 140,318 Great Britain Mar. 25, 1920 537,757 Great Britain Aug. 15, 1941 

3. A SEPARABLE ELECTRICAL CONNECTOR COMPRISING IN COMBINATION A SOCKET CONTACT AND A PIN CONTACT ADAPTED TO BE RECEIVED WITHIN AND MAKE ELECTRICAL CONTACT WITH THE SOCKET CONTACT, AN AXIALLY EXTENDING CONDUCTOR, SAID PIN CONTACT COMPRISING A PLURALITY OF FINGER MEMBERS RADIALLY DISPLACED FROM SAID CONDUCTOR AND ELECTRICALLY CONNECTED THERETO, A HEAT-EXPANSIBLE MEMBER POSITIONED BETWEEN EACH OF SAID FINGER MEMBERS AND SAID CONDUCTOR WHEREBY UPON A RISE IN TEMPERATURE SAID HEAT-EXPANSIBLE MEMBER WILL EXPAND AND BACK UP SAID FINGER MEMBERS. 